Industrial gas turbine exhaust system with modular struts and collars

ABSTRACT

An integrated single-piece exhaust system (SPEX) with modular construction that facilitates design changes for enhanced aerodynamics, structural integrity or serviceability. The SPEX defines splined or curved exhaust path surfaces, such as a series of cylindrical and frusto-conical sections that mimic curves. The constructed sections may include: (i) a tail cone assembly fabricated from conical sections that taper downstream to a reduced diameter; or (ii) an area-ruled cross section axially aligned with one or more rows of turbine struts; or both features. Modular inner and outer diameter inlet lips enhance transitional flow between the last row blades and the SPEX, as well as enhance structural integrity. Modular strut collars have large radius profiles between the SPEX annular inner diameter and outer diameter flow surfaces, for enhanced airflow and constant thickness walls for uniform heat transfer and thermal expansion. Scalloped mounting flanges enhance structural integrity and longevity.

CROSS-REFERENCE TO RELATED APPLICATIONS

The following family of five related co-pending United States utilitypatent applications is being filed concurrently on the same date, whichare all incorporated by reference herein:

“Industrial Gas Turbine Exhaust System With Splined Profile Tail Cone”,filed on ______, Ser. No. unknown, file 2013P02367US;

“Industrial Gas Turbine Exhaust System Diffuser Inlet Lip”, filed on______, Ser. No. unknown, file 2013P18971US;

“Industrial Gas Turbine Exhaust System With Area Ruled Exhaust Path”,filed on ______, Ser. No. unknown, file 2013P18972US;

“Industrial Gas Turbine Exhaust System With Modular Struts and Collars”,filed on ______, Ser. No. unknown, file 2013P18973US; and

“Modular Industrial Gas Turbine Exhaust System”, filed on ______, Ser.No. unknown, file 2013P18974US.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention relate to industrial gas turbine exhaustsystems, and more particularly to modular design, drop-in exhaustsystems with a plurality of available enhanced exhaust flow pathaerodynamic features, including, among others: flow path transition atthe last blade row and diffuser interface inner and/or outer diameters;diffuser flow path angles that individually and severally in variouscombinations suppress flow separation and enhance pressure recovery;extended center body with a splined, compound curve tail cone or amulti-linear tail cone mimicking a splined compound curve; and turbineexhaust strut shapes with reduced trailing edge radius and increasedmanifold cast collar flow path radii. Embodiments of the modular drop-inexhaust system invention are also directed to enhanced structuralintegrity and serviceability features, including among others: last rowturbine blade accessibility; turbine exhaust case (TEC) and/or turbineexhaust manifold (TEM) support struts with constant thicknessvertical/radial cross section collars; modular support struts; single-or multi-radius, scalloped mounting flanges for fatigue resistance;enhanced mounting flange accessibility and mounting flange fastenerreplacement. The various features described herein may be utilizedjointly and severally, in any combination.

2. Description of the Prior Art

Industrial gas turbine (IGT) exhaust system design often requirebalancing of competing objectives for aerodynamic efficiency, structurallongevity, manufacture ease and cost, as well as installation and fieldservice ease. For example, an IGT exhaust system designed to satisfyonly aerodynamic objectives might comprise one or more metalcastings/fabrications mimicking the construction of the compressor,combustor and/or turbine sections, airflow-optimized for the engine.That aero-optimized design casting/fabrication would not be readilyadaptable to accommodate airflow parameters if other portions of the IGTdesign were modified. For example, the exhaust system would need to bere-optimized (with the expense of new castings/fabrications) if newturbine blade/vane designs were incorporated into the engine. Onlyspecific portions of the aero optimized design castings/fabricationsmight experience thermal damage necessitating replacement after service,while other portions might not experience any discernible wear.Replacement of the entire exhaust as a repair solution for onlylocalized wear would not be cost effective. A more desirablemanufacturing and/or service repair solution would be creation of anexhaust system design (including, by way of example, a modular exhaustsystem design) that facilitates replacement of worn portions andperiodic upgrades of the system (including upgrades to increase exhaustsystem longevity and durability as their needs are recognized over time)without requiring redesign and fabrication of an entirely new exhaust.Exhaust system manufacturing and service objectives include ease ofinitial manufacture, installation, field repair and upgrades during theservice life of the IGT engine with minimal service downtime, so thatthe engine can be utilized to generate power for its electric grid.

Some known IGT exhaust designs are shifting to so-called single pieceexhaust systems (SPEX) that in some cases facilitate drop-in connectionto the turbine section. Some of these SPEX designs couple a generallyannular turbine exhaust case (TEC) to the downstream portion of the IGTengine turbine section, and in turn couple a separate turbine exhaustmanifold (TEM) to a downstream end of the TEC. Both the TEC and TEM havediffuser sections that mate to each other and when so mated form innerand outer exhaust cases. The turbine exhaust path is formed betweeninner facing opposed surfaces of the inner and outer exhaust cases. Forease of manufacture the TEC and TEM diffuser sections that form theinner and outer exhaust cases are fabricated primarily from weldedsections of rolled steel that are structurally separated by outwardlyradially oriented struts having airfoil cross sections. The inner andouter exhaust cases sections generally comprise serially joinedcylindrical and frusto-conical sections with generally sharp angularchanges between the sections, due to the relatively small number ofjoined sections. Sharp angular changes do not generally foster smoothlaminar exhaust airflow and encourage boundary flow separation, leadingto energy wasting turbulence and backpressure increase. While smootherairflow would be encouraged by use of more gently curving interiorsurface annular constructions, they are relatively expensive to producegiven the large diameter of IGT exhausts. Also as previously noted, itis expensive fabricate new casting/fabrication designs necessitated bychanges in the IGT flow properties (e.g., new turbine blades airflowproperties) or other need to upgrade (e.g., for improved exhaustlongevity). It would be preferable to construct IGT exhaust systems frommodular components that can be reconfigured and assembled foroptimization of changed IGT flow properties rather than having to createan entirely new exhaust system design when, for example, changingturbine blade designs.

Thus, a need exists in the art for an industrial gas turbine drop-inexhaust system with modular construction that facilitates design changesfor any one or more of enhanced aerodynamics, structural integrity orserviceability, for example for optimization of exhaust flow whenchanging turbine blade designs.

SUMMARY OF THE INVENTION

Accordingly, an object of the invention is to create an industrial gasturbine exhaust system with modular construction that facilitates designchanges for any one or more of enhanced aerodynamics, structuralintegrity or serviceability, in response to changes in the upstreamsections of the IGT, for example changes in the turbine blades.

These and other objects are achieved in accordance with embodiments ofthe invention by an industrial gas turbine (IGT) drop-in single-pieceexhaust system (SPEX) with modular construction comprising a turbineexhaust case (TEC) mated to a turbine exhaust manifold (TEM) that haveinner and outer exhaust cases constructed of a series of cylindrical andfrusto-conical sections that mimic curves. In some embodiments theconstructed sections include: (i) a splined (compound curve) tail coneassembly, including, by way of example, a tail cone assembly that isfabricated from a plurality of frusto-conical sections that taperdownstream to a reduced diameter; or (ii) an area-ruled cross sectionaxially aligned with one or more rows of turbine struts to compensatefor strut reduction in exhaust flow cross section through the SPEX; orboth features.

In other embodiments the tail cone and/or area ruled section is combinedwith an inlet section comprising a pair of adjoining first and seconddecreasing angle frusto-conical sections. In some embodiments the SPEXinlet includes an outer diameter modular stiffening ring with a lip andan inner diameter chamfered stiffening ring, both stiffening rings beingoriented toward the turbine centerline for enhanced transitional flowbetween the last row blades and the TEC and enhanced TEC structuralintegrity. The respective inner and/or outer stiffening rings profilescan be optimized for airflow enhancement with specific turbine bladedesigns. Modular stiffening ring construction facilitates matchedreplacement with different blade designs merely by substitutingdifferent inner and/or outer stiffening ring sets into SPEX structuresfor different blade and/or IGT engine configurations.

Embodiments of the invention include TEC and/or TEM strut collars havingincreased acute angle side fillet radius profiles between the SPEXannularly-oriented inner and outer exhaust case inner diameter and outerdiameter flow surfaces, for enhanced airflow. The strut collars aremodular for facilitating changes or upgrades to the SPEX airflowcharacteristics (e.g., airflow characteristic changes caused bydifferent turbine blade replacements) and easier replacement of worncollars in a new manufacture or extensive refurbishment facility. Insome embodiments the collars have constant thickness vertical/radialcross section for uniform heat transfer and thermal expansion, so as toreduce likelihood of hot spot formation, burn through as well thermal orvibrational induced cracking of the TEC structure.

Other embodiments of the invention further enhance SPEX structuralintegrity and longevity by utilization of the previously identifiedconstant thickness vertical/radial cross section strut collars on eitheror both strut inner diameter and outer diameter ends.

Additional embodiments of the invention incorporate scalloped mountingflanges at the TEC/TEM diffuser sections mating interface that whenjoined form the inner and outer exhaust cases, for enhanced SPEXstructural integrity and longevity.

Embodiments of the invention include segmented access covers formed inthe TEC diffuser section that forms the inner exhaust case thatfacilitate access to the last row turbine blades.

Yet other embodiments of the invention also facilitate installation andmaintenance of the aforementioned multi-segment frusto-conical exhausttail cone through accessible and easily replaceable fastening mountingstructures.

More particularly the present invention described herein features, Anindustrial gas turbine exhaust system, comprising an inner case; anouter case circumscribing the inner case in spaced relationship relativeto a centerline defined by the exhaust system; and a turbine exhaustpath defined between the outer and inner cases. A plurality of struts isinterposed between the outer and inner cases that are tilted at an anglerelative to a radius defined by the exhaust system centerline. A strutcollar is coupled to an end of at least one strut and its respectiveabutting outer or inner case. The collar outer surface has a constantfillet radius external profile on an acute angle side thereof for smoothexhaust flow transition between its respective strut and abutting casesurface. The fillet radius profile has a range of about 15%-40% of strutmaximum thickness.

The present invention described herein also features an industrial gasturbine apparatus, comprising a compressor section; a combustor section;a turbine section including a last downstream row of turbine blades thatare mounted on a rotating shaft; and an industrial gas turbine exhaustsystem. The exhaust system has a turbine exhaust case (TEC) coupled to adownstream end of the turbine section; an inner case; an outer casecircumscribing the inner case in spaced relationship relative to acenterline defined by the exhaust system; and a turbine exhaust pathdefined between the outer and inner cases, extending downstream of theturbine blades. A plurality of struts is interposed between the outerand inner cases that are tilted at an angle relative to a radius definedby the exhaust system centerline. A strut collar is coupled to an end ofat least one strut and its respective abutting outer or inner case. Thecollar outer surface has a constant fillet radius external profile on anacute angle side thereof for smooth exhaust flow transition between itsrespective strut and abutting case surface. The fillet radius profilehas a range of about 15%-40% of strut maximum thickness.

Additionally, the present invention described herein features a methodfor fabricating an industrial gas turbine exhaust system. The methodincludes simulating an operating gas turbine exhaust flow in a simulatedgas turbine exhaust system exhaust path between interior facing surfacesof a simulated turbine exhaust inner case and outer case. A plurality ofsets of simulated gas turbine exhaust system struts is provided. Thestruts are tilted at an angle relative to a radius defined by theexhaust system centerline. A plurality of mating strut collars havingdifferent surface profiles is also provided. Each provided collar has anouter surface having a constant fillet radius external profile on anacute angle side thereof and each collar is adapted for coupling to anend of its corresponding strut and a mating inner or outer case interiorsurface. A plurality of a first set of simulated struts and mating strutcollars are interposed between the simulated outer and inner cases andfirst simulated exhaust flow characteristics are monitored. A second setof simulated struts and mating strut collars are interposed between thesimulated outer and inner cases and second simulated exhaust flowcharacteristics are monitored. The first or second set of simulatedstruts and mating strut collars are selected for fabrication of a gasturbine exhaust system based at least in part on the first and secondsimulated exhaust flow characteristics. The gas turbine exhaust systemis fabricated in conformance with the simulated outer cases and theselected first or second set of simulated struts and mating strutcollars.

The objects and features of the present invention may be applied jointlyor severally in any combination or sub-combination.

BRIEF DESCRIPTION OF THE DRAWINGS

The teachings of the various embodiments of the invention can be readilyunderstood by considering the following detailed description inconjunction with the accompanying drawings, in which:

FIG. 1 is a cross section of the top half of an industrial gas turbine(IGT) incorporating an embodiment of the single piece exhaust system(SPEX) of the invention, comprising the mated TEC and TEM componentsthat form the inner and outer exhaust cases and the exhaust flow pathbetween opposed inner surfaces of those cases;

FIG. 2 is a perspective cross sectional view of the SPEX of FIG. 1removed from the IGT;

FIG. 3 is a front, upstream perspective view of the SPEX of FIG. 1;

FIG. 4 is a schematic cross section of the SPEX of FIG. 1, identifyingaerodynamic features of the SPEX drop-in turbine exhaust case (TEC) andturbine exhaust manifold (TEM) that when mated form the inner and outerexhaust cases, and which define the exhaust gas path of the invention;

FIG. 5 is a schematic cross section of a SPEX, similar to that of FIG.4, identifying an area ruled, wasp-like reduced inner diameter sectionthat is axially aligned with the rear TEM struts, in accordance with analternative embodiment of the invention;

FIG. 6 is a cross section of a TEC outer diameter diffuser stiffeningring of FIG. 4, formed in the turbine exhaust outer case, in accordancewith an embodiment of the invention;

FIG. 7 is a cross section of the TEC inner diameter diffuser stiffeningring of FIG. 4, formed in the turbine exhaust inner case, in accordancewith an embodiment of the invention;

FIGS. 8A, 8B and 9-11 are perspective views of a segmented forward innerdiameter cut out and access cover of the TEC, for service access to lastrow turbine blades, in accordance with an embodiment of the invention;

FIG. 12 is a perspective view of a TEC outer diameter (OD) seal flange,in accordance with an embodiment of the invention;

FIGS. 13 and 14 are respective fragmented front elevational and crosssectional views of a TEC/TEM interface aft OD flange, in accordance withan embodiment of the invention;

FIGS. 15 and 16 are respective fragmented front elevational and crosssectional views of a TEC/TEM interface aft inner diameter (ID) flange,in accordance with an embodiment of the invention;

FIG. 17 is a schematic front, upstream elevational view of the SPEX ofFIGS. 1 and 3, showing the annular cross section exhaust path formedbetween the inner and outer cases as well as the tilted TEM and TECstruts that maintain spaced separation between the respective cases;

FIGS. 18 and 19 are respective perspective and cross sectional views ofan forward TEC strut ID cast collar in accordance with an embodiment ofthe invention;

FIGS. 20 and 21 are respective perspective and cross sectional views ofan aft TEM strut OD cast collar in accordance with an embodiment of theinvention;

FIG. 22 is a cross sectional view of an aft TEM strut planform, inaccordance with an embodiment of the invention;

FIG. 23 is a quartered cross-sectional view of the SPEX outlet airflowpath including the tail cone, in accordance with an embodiment of theinvention;

FIG. 24 is an axial elevational view of the tail cone of FIG. 23,showing the removable aft tail cone section and mating cap/coverassemblies for service access to the IGT bearing housing in the TEC, inaccordance with an embodiment of the invention;

FIG. 25 is a cross sectional view of the aft tail cone sectionattachment mechanism, taken along 25-25 of FIG. 24, in accordance withan embodiment of the invention; and

FIG. 26 is a perspective view of a nut plate of the aft tail conesection attachment mechanism, in accordance with an embodiment of theinvention.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures.

DETAILED DESCRIPTION

After considering the following description, those skilled in the artwill clearly realize that the teachings of embodiments of the inventioncan be readily utilized in by an industrial gas turbine (IGT) drop-insingle-piece exhaust system (SPEX) with modular construction comprisinga turbine exhaust case (TEC) mated to a turbine exhaust manifold (TEM),which when combined form opposed inner and outer exhaust cases thatdefine an exhaust flow path. The inner and outer exhaust cases areconstructed of a series of splined, compound curves and/or ofcylindrical and frusto-conical sections that mimic splined curves. Othermodular portions of the SPEX can be utilized jointly and severally asneeded to enhance airflow characteristics, including by way of example:(i) a splined, compound curve tail cone assembly that may be fabricatedfrom a plurality of frusto-conical sections that taper downstream to areduced diameter; (ii) an area-ruled cross section axially aligned withone or more rows of turbine struts to compensate for strut reduction inexhaust flow cross section through the SPEX; (iii) an inlet sectioncomprising a pair of adjoining first and second decreasing anglefrusto-conical sections; (iv) inner and outer diameter modularstiffening rings oriented toward the turbine centerline for enhancedtransitional flow between the last row blades and the TEC and forenhanced TEC structural integrity; (v) modular replaceable strut collarshaving constant radius fillet profiles between the SPEX annular exhaustpath inner diameter and outer diameter flow surfaces, for enhancedairflow. Other modular components of the SPEX can be utilized jointlyand severally as needed to enhance integrity and longevity, including byway of example: (i) constant thickness vertical/radial cross sectionmodular strut collars on either or both strut inner diameter and outerdiameter ends; (ii) scalloped mounting flanges at the TEC/TEM interface;(iii) segmented access covers in the TEC diffuser section forming theinner exhaust case, for facilitating access to the last row turbineblades; and (iv) enhanced mounting structures for facilitatinginstallation and maintenance of the aforementioned splined curve profileexhaust tail cone, such as a multi-segment frusto-conical exhaust tailcone mimicking a splined curve profile tail cone through accessible andeasily replaceable fastening mounting structures.

FIG. 1 shows an axial quarter sectional view of industrial gas turbine(IGT) 40 of the type used to generate power for an electric grid. TheIGT includes compressor 42, combustion 44 and turbine 46 sections, withthe turbine section including a last row of turbine blades 48. Asingle-piece exhaust system (SPEX) 50 that is constructed in accordancewith an embodiment of the invention is coupled to the IGT 40 downstreamof the turbine section 46. The last row turbine blades 48 are orientedin spaced relationship and in communication with the SPEX 50, so thatthe rotating blades do not contact the SPEX during the IGT 40 operationcycle.

Referring to FIGS. 1-3, the SPEX 50 comprises a generally annular-shapedturbine exhaust casing (TEC) 60, with a TEC outer casing 61 that iscoupled to the turbine section 46. A bearing housing 62 is centeredwithin TEC outer casing 61 by TEC forward support struts 68. Asingle-piece diffuser section is retained within the TEC 60 outer case61. The SPEX 50 also comprises a turbine exhaust manifold (TEM) 70 witha single piece diffuser section that mates with the TEC 60 diffusersection. Referring also to FIG. 17, the combined, mated TEC/TEM diffusersections form an outer exhaust case 72 and an inner exhaust case 74, theopposed inner surfaces of which define an annular exhaust flow path. Theouter and inner exhaust case structures 72, 74 are supported in theirspaced relationship by six forward TEC support struts 100 and three aftor rear TEM support struts 110. Each TEC support strut 100circumferentially envelops its corresponding TEC forward support strut68 in nested fashion. The TEM 70 is coupled to the TEC outer casing 61by support rods 64. Cover plates 66 bridge and cover the circumferentialgap between the TEC 60 and TEM 70. The TEM 70 is also mated and coupledto the TEC 60 by interface flanges 140 and 150 that will be described ingreater detail herein with respect to the description of FIGS. 12-16.The TEM 70 can be replaced, when worn or upgraded, as a single-piece,drop-in unit by uncoupling it from the TEC 60. In this manner the TEC 60casing 61, its rotor bearings and other structures do not have to bedisturbed when replacing the TEM 70, shortening service disruptions.

FIG. 4 shows schematically a quartered sectional view of the SPEX 50 andits structural features that define the exhaust gas flow path from leftto right. Starting at the SPEX inlet end adjoining the turbine section40, the TEC diffuser portion that forms the outer exhaust case 72 has afirst frusto-conical diffuser cone section 76A defining an angle αrelative to the IGT 40 centerline. The angle α is preferably chosen tomatch or is less than the corresponding blade tip angle δ′, shown inFIG. 6. A second frusto-conical diffuser cone section 76B, formed by themating (at interface flange 140) TEC 60 and TEM 70, defines an angle βthat preferably is shallower than angle α, as has been constructed insome previously known turbine exhaust systems. TEC 60 frusto-conicaldiffuser section 76C defining an angle γ establishes the opposing innerdiameter portion of gas flow path. The diffuser section 76C divergingangle γ may be used to increase the enveloped volume within the SPEX 50inner case 74 for increased service accessibility to turbine componentsenveloped within the inner case, such as the bearing housing 62.Alternatively the diverging angle γ may be decreased (i.e., negativeangle), in order to increase the exhaust flow path cross sectional area.The SPEX 50 diffuser portion frusto-conical cone angles α, β and γ areselected so that exhaust system inner diameter angle γ is sufficientlylarge to provide for desired turbine component serviceability volume,without unduly hampering exhaust flow efficiency. Therefore, angle βgenerally increases in response to an increase in angle γ so thatexhaust flow is not constricted within the annular cross section betweenthe diffuser cone sections 76B and 76C. Exemplary angular ranges are αbetween approximately 6 to 19 degrees; β approximately 4 to 13 degreesand γ approximately −3 to +5 degrees.

Downstream and adjoining the ID and OD frusto-conical sections 76A-C isa cylindrical section defined by OD section 78A and ID section 78B. Asplined (smooth curve profile) tail cone assembly 79 is affixed to theID cylindrical section 78B and comprises four frusto-conical sections79A-D that approximate a splined curved profile. Alternatively a splinedsingle piece or multi-piece tail cone assembly may be substituted forthe four frusto-conical sections 79A-D. Tail cap or cover 79E is affixedto the frusto-conical aft tail cone section 79D, to complete the shapeof the extended tail cone assembly 79. Thus the SPEX 50 is constructedof a plurality of fabricated frusto-conical and cylindrical sections 76,78, 79 that approximate splined, curved profiles for promotion of smoothexhaust gas flow and reduced back pressure. The sections 76, 78 and 79are preferably constructed of known rolled sheet steel that are weldedto form the composite SPEX 50. Due to the modular, fabricatedconstruction, the SPEX 50 airflow profile may be modified bysubstituting different fabricated sections 76, 78 and 79 to form theouter 72 and inner 74 exhaust cases that are deemed best suited for aparticular IGT 40 application. The fabricated section 79 can befunctionally replaced by a single or multi-component tail cone formed bycasting, forging, spin-forming or composite winding (e.g.carbon-carbon). Exemplary tail cone sections 79A-Dlength/diameter (L/D)ratios and angular ranges are set forth in Table 1:

TABLE 1 Segment L/D (percentage) Angular Range (Degrees) 79A 10%-20% 3-779B 10%-20%  8-12 79C 10%-20% 13-17 79D 40%-70% 18-22

An alternate embodiment TEC 70′ is shown in FIG. 5, its primarydistinguishing difference from the embodiment of FIG. 4 being a TEMinner case 74′ with a narrowed, area ruled section 75′ for increasingannular cross section of the exhaust gas flow path and therebycompensating for the flow restriction caused by the aft TEM struts 110(those struts are described subsequently in greater detail herein). Theruled section 75′ can be constructed from a pair of oppositely orientedfrusto-conical sections and an adjoining cylindrical section 78B′ thatadjoins the tail cone section 79. Alternatively, the annular crosssection may be increased by forming an area ruled section 75″ on the TEMdiffuser portion forming the outer case 72″ or a combination of bothtypes of area ruled sections 75′, 75″.

Further SPEX 50 airflow enhancements are achievable by introduction ofouter diameter (OD) stiffening ring 80, whose airflow characteristicscan be modified for compatibility with different turbine blades 48. TheOD stiffening ring 80 effectively bridges a potential airflow leakagegap between the turbine blades 48 and the outer exhaust case 72.Referring to FIG. 6, the OD stiffening ring 80 is coupled to the TECfirst diffuser cone 76A and includes a chamfered entrance 82 thatreduces likelihood of backpressure that might otherwise occur if it werea sharp edge. A generally annular notch 83 optionally is formed in theOD stiffening ring 80 downstream the chamfered entrance 82 having anaxial length L₈₃ and depth D₈₃ whose respective dimensions are chosen toprovide clearance for the turbine blades 48 during the turbine 40operational cycles. The OD stiffening ring 80 also defines a convex lip84 with a radius that is oriented toward the IGT 40 centerline andtransitions to a ramped diverging cone 86 that defines an angle δ withrespect to the centerline. The angle δ preferably matches, or is lessthan, the blade tip angle δ′. Similarly, the first diffuser cone section76A angle α matches or is less than angle δ. OD stiffening ring trailingend 88 is coupled to the TEC 60 adjoining first diffuser cone 76A.

Complimentary inner diameter (ID) stiffening ring 90 (FIG. 7) similarlyenhances airflow characteristics and can be modified for compatibilitywith different turbine blades 48. The ID stiffening ring 90 effectivelybridges a potential airflow leakage gap between the root portion of therespective the turbine blades 48 and the inner exhaust case 74 formed bythe TEC 60. Referring to FIG. 7, the ID stiffening ring 90 has achamfered profile 92 of approximately 10-30 degrees relative to theexhaust path cross section. The chamfer 92 should be of sufficient axiallength to insure no forward facing step from the blade 48 flow path tothe SPEX 50 flow path. The chamfered surface 92 facilitates smoothairflow transition from the blades to the SPEX 50. Otherwise, a sharpedge at the location of the chamfered profile 92 would increase thepossibility of backpressure. The ID stiffening ring 90 includes aninwardly oriented portion 94 and a generally cylindrical section 96 thatis joined to the inner exhaust case 74 frusto-conical sections 76C.Profiles of the ID stiffening ring 90 chamfer 92 and inwardly orientedportion 94, as well as the axial separation gap L₉₄ between the ring andblades 48 are preferably selected for airflow compatibility with a givenblade set 48. Thus, the ID stiffening ring 90 as well as the ODstiffening ring 80 profiles and blade set 48 may be selected anddesignated as a modular matched set to be installed together during agas turbine 40 initial manufacture or subsequent rebuild/retrofit.

In addition to the aforementioned airflow enhancements, the respectiveOD stiffening ring 80 lip 84 and ID stiffening ring 90 portion 94enhance TEM 70 structural strength and rigidity, which in turn betterassure consistent airflow cross section, resist thermal deformation andlessens exhaust pulsation-induced vibration/noise.

The TEC 60 incorporates an access cut out and service access cover 120on the twelve o'clock circumferential position for last row turbineblade 48 and rotor balancing service access, as shown in FIGS. 8A and 8Band 9-11. While access cut outs have been used in the past, prior cutouts did not have sufficient axial length to accommodate replacement ofnewer generation, larger width last row turbine blades. Merelyincreasing axial length of existing cut out and cover single-piecedesigns introduces structural reinforcement challenges that ultimatelyincrease service time for cover removal and reinstallation. The newembodiment service access cover 120 of the present invention hasstructural and functional flexibility to accommodate access andreplacement of a wider range of last row turbine blades 48 byincorporating a pair of first and second segmented covers 122 and 126.The first access cover 122 is easily removed for rotor balancingservices and incurs no significant additional outage time during thatservice procedure. The second access cover is removed during morecomplex outages requiring turbine blades 48 removals. As shown in FIG.9, lateral axial periphery of the cutout is reinforced by service accesscover supports 121. Both the access covers 122 and 124 rest on and iscoupled to the cover supports 121. The first access cover 122 has afirst segment front lip 124 for aerodynamic functional continuity of theTEM ID ring lip 94, while the aft portion of the cover rests on and iscoupled to the second cover flange 127.

The TEC casing 61 60 and TEC 70 diffuser portion 76A-C are coupled toeach other in nested orientation by forward OD and ID interfaces 130,134, that include known finger seals, which are coupled to scallopedflanges, such as the scalloped flange 132 of OD interface 130 (see FIGS.1 and 12). OD and ID aft seal flanges interfaces 140, 150 are shown inFIGS. 13-16. Each aft flange interface also includes respectivemulti-radius scalloped flanges 142, 152, defining through bores 144, 154for receipt of fasteners 146, 156. Each scalloped flange 142 has amulti-radius, compound curve profile, with a first curved edge 141Adefining a radius r_(141A) transitioning to a second, longer orshallower radius portion 141B of radius r_(141B) that is 10-13 timeslonger than r_(141A) and back to a third curved edge 141C with radiusr_(141C) that generally matches r_(141A). Scalloped flange 152 similarlydefines a multi-radius curved profile 151A-151C with similarlyrelatively proportioned radii r_(141A)-r_(151C). Each respectivescalloped flange 142, 152 mates with a corresponding TEM 70 flange. Themating flange pairs are fastened together with the respective fasteners146, 156. The scalloped flanges 132, 142, 152 improve structural and gasflow sealing integrity by each individual scallop being independentlyflexible relative to all of the other scallops that collectively formthe entire circumferential flange structure. Individual scallop flexurecapability accommodates localized thermal, mechanical and vibrationalstress without buckling, cracking or otherwise deforming the rest of thecircumferential flange. The multi-radii scalloped flanges 142, 152increase structural integrity of the assembled SPEX 50 and reduces lowcycle structural fatigue that is induced during the cyclic temperaturevariations inherent in IGT engine 40 start/operation/stop for periodicinspection and service cycles.

Another modular construction feature of embodiments of the inventionthat enhance aerodynamic, structural and manufacture/service performanceof the SPEX 50 are modular TEC collars 102, 104 for the TEC frontsupport strut 100 and modular TEM collars 112, 114 for the TEM rearsupport strut 110, shown schematically in FIGS. 4 and 17. The modularcollars 102, 104, 112, and 114 are welded to the elongated supportmember portion of their corresponding struts 100 or 110 and thecorresponding inner or outer diameter of the TEM 70 surfaces that formthe annular gas flow path. Aerodynamic performance of the fore and aftstrut/ID-OD diffuser interfaces can be altered by substitution ofdifferent modular collars that are optimized for specific IGTapplications. In new manufacture IGTs, one of a family of struts andcollars can be chosen to optimize or enhance a specific IGT turbineblade 48 configuration. Later, during subsequent service maintenance,the struts and associated collars can be upgraded or replaced to enhanceaerodynamic flow properties of the SPEX 50 in response to other changes(e.g., new turbine blading) made within the IGT 40.

As shown in FIG. 17, support struts 100 and 110 are often leanedtangentially at angle θ relative to the exhaust system 50 radial axes toreduce the thermally induced stresses in typical ring-strut-ringconfigurations. However, there is a support strut design thermal stressmitigation and aerodynamic efficiency tradeoff Compared to radiallyoriented struts, the leaned struts generally increase aerodynamic lossesby increasing the total amount of blockage in the flow path and byincreasing the local flow diffusion in the acute angle corners (seee.g., R_(B) and R_(D) fillet radius reference locations in FIG. 17) madeby the strut surface and the flow path. The diffusion increase occursbecause, on the acute angle side, the leaned strut surface faces anddirectly interacts with the local flow path end wall. As flow travelsaft from the strut leading edge (LE), it is accelerated to highervelocities because the increasing thickness of the strut essentiallysqueezes the flow against the end wall. The opposite happens as the flowtravels aft from the strut maximum thickness location. In this case thestrut thickness (or blockage) decreases quickly which, in turn, quicklyincreases the available flow area, and causes higher local flowdiffusion. Increased diffusion can lead to flow separation and hightotal pressure loss. The effect increases with strut lean angle, strutmaximum thickness, flow Mach number and strut incidence. The aerodynamicpenalty for leaned struts can be mitigated by use of large fillets inthe acute angle corners. For relatively thick struts that are leaned 20to 30 degrees (θ) performance loss can be minimized by use of filletswith a radius (R_(B), R_(D)) of 15 to 40% of the strut maximumthickness. For these purposes, struts can be considered relatively thick(or fat) when they exceed a maximum thickness to chord ratio of 25%. Thefillet sizes applied to the acute angle corners should be increased forhigher leans and thicker struts and reduced for lower leans and thinnerstruts. Fillet radii R_(A), R_(C) on the obtuse angle side of the strut110, 112 is not aerodynamically critical. Changes in turbine blade 48flow properties impacts exhaust system aerodynamic efficiency and oftenrequire re-optimization of support strut/exhaust case interface acuteangle fillet radius R_(B), R_(D).

Modular strut collars 102, 104, 112 and 114 that constructed inaccordance with embodiments of the present invention facilitaterelatively easy change in strut angle θ, if required to do so forstructural reasons as well as the acute angle fillet radii R_(B), R_(D)when required to optimize aerodynamic efficiency changes in blade 48aerodynamic properties. The modular strut collars of the presentinvention also balance thermal stress constraints while optimizingaerodynamic efficiency. FIGS. 18 and 19 show an exemplary ID TEC collar104, featuring aerodynamically enhancing constant fillet radius R_(A),R_(B) flow path fillets. Similarly, FIGS. 20 and 21 show an exemplary ODTEM collar 112 with constant fillet radius R_(C),R_(D) flow path filletsto increase service life of the SPEX. Generally for aerodynamicefficiency, the respective strut collars 104, 112 acute angle filletradii R_(B) and R_(D) is chosen as a function of the strut centerlinetilt angle θ relative to the SPEX 50 radius and strut maximum thickness.

As the respective strut collars 104, 112 obtuse angle fillet radii R_(A)and R_(C) are not critical to aerodynamic performance their radii arechosen to benefit exhaust case/strut interface thermal fatigueresistance to provide for collar 104, 112 constant thicknesses in agiven radial orientation (i.e., the vertical direction in FIGS. 19 and21). Desirably the strut collars 102, 104, 112 and 114 have radially orvertically oriented constant thickness cross sections on the obtuseangle sides R_(A), R_(C) that preferably vary by no more than +1-10percent for uniform heat transfer, structural and thermal stressresistance strength and more uniform expansion and extended bases forincreased contact with respective mating ID or OD TEM surfaces. It isalso preferred that the respective strut collars have thicknessapproximating thickness of the mating exhaust inner or outer case 72,74, but due to fabrication and structural/fatigue strength constraintsvertical cross sectional thickness on the acute angle circumferentiallocations may be 50-250% greater than the mating exhaust case thickness.Strut collar cross sectional thickness may vary about the strutcircumference, but it is desirable to maintain constant thicknessvertical cross section preferably varying by no more than 10% at anygiven circumferential location. On the acute angle circumferentialportions of the strut collar thickness may vary by up to 250%. Strutcollars 102, 104, 112 and 114 that preferably incorporate constantvertical thickness at any circumferential location and that preferablymatch thickness of the mating exhaust case 72, 74 reduce likelihood ofcracking or other separation from the TEM during IGT operation, whichextends SPEX 50 service life. The strut collars 102, 104, 112 and 114are cast, forged or fabricated from formed metal plates.

The TEM strut 110 aerodynamic footprint is shown in FIG. 22. The strut110 features an extended length axial chord length L, with a relativelysharp trailing edge radius R_(E) for enhanced aerodynamic performance.Exemplary trailing edge radii R_(E) range from 10 to 20% of the strutchord, facilitating a thin trailing edge thickness (TET) and can be usedeffectively with struts of maximum thickness W to chord length L ratioof up to 40%. The multi-segmented tail cone 79 structural features arehighlighted in elevational view FIG. 23. Compared to known tail conesthat incorporate a single frusto-conical profile tail cone, tail conesof the present invention incorporate splined, curved tail cones orplural serial axially aligned frusto-conical sections that mimic asplined curved profile. In the embodiment of FIG. 23 the tail coneincorporates first through third frusto-conical sections 79 A-C and afrusto-conical tail cone section 79D that terminates in an aft cap orcover 79E. While the exemplary tail cone 79 embodiment of FIG. 23incorporates four frusto-conical sections, tail cones having two or moresuch sections can be fabricated. Exemplary tail cone sections 79A-Dlength/diameter (L/D) ratios and angular ranges were previously setforth in Table 1. The length of the tail cone 79 (from the TEM strut 100trailing edge) should range from about 1 to 1.5 diameters of theupstream exhaust inner case 74 ID cylindrical center body 78B. Thisallows significant aerodynamic benefit without introducing excessivecantilevered mass that can introduce low mechanical natural frequencies.The tail cone should reduce the exhaust inner case 74 cylindrical centerbody 78 exit area by about 50 to 80% in a smooth splined or piece-wisesmooth fashion (e.g., by joinder of frusto-conical portions such as79A-D), so as to not cause premature flow separation. The achievablearea reduction will depend on the local exhaust flow field of thediffuser. For example, hub strong velocity profiles in a moderatelydiffusing flow path will allow for shorter tail cones with low exitarea. The opposite is true for OD strong velocity profiles and stronglydiffusing flow paths.

The aft tail cone 79D and aft cap 79E sections are secured to the TEM 70by a fastening system (FIGS. 24-26) that facilitates easy removal andreinstallation for IGT rear bearing and other maintenance/inspectionservices. The fastening system features sector-shaped nut plates 160that incorporate replaceable female threaded inserts 162, such asHELICOIL inserts. Using the aft tail cone 79D attachment structure ofFIG. 25 as an example, the third tail cone 79C ring flange 164 iscoupled to the tail cone extension ring flange 166 by threaded fasteners168 that pass through bores defined by each flange. The fasteners 168are threaded into the nut plate 160 female threaded inserts 162. The nutplates 160 offer easier fabrication and replacement (includingreplacement of worn female threaded inserts 162) than commonly usedpermanently welded in place threaded nuts.

The SPEX 50 exhaust system modular construction of OD stiffening ringwith δ, ID stiffening ring, variable diffuser angles α,β, γ, modularruled area, modular support struts 110, 112 with modular collarsfacilitate relatively easy optimization of exhaust system aerodynamicand structural properties in response to changes in turbine blade 48airflow properties. The modular components can be configured via virtualairflow and thermal simulation, with the virtual components utilized astemplates for physically manufactured components. Component sets ofturbine blades and exhaust system modular components can be matched foroptimal performance, comparable to a kit of parts adapted for assemblyinto a complete IGT 40 and exhaust system 50. Therefore a change inturbine blade 48 configuration/airflow properties can be accommodated inan original build, service or field repair facility by modularreplacement of exhaust system components to assure that the new IGT 40blade/exhaust system 50 configuration optimized for exhaust airflow andstructural performance.

Although various embodiments that incorporate the teachings of theinvention have been shown and described in detail herein, those skilledin the art can readily devise many other varied embodiments that stillincorporate these teachings. The invention is not limited in itsapplication to the exemplary embodiment details of construction and thearrangement of components set forth in the description or illustrated inthe drawings. The invention is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that the phraseology and terminology used herein is for thepurpose of description and should not be regarded as limiting. The useof “including,” “comprising,” or “having” and variations thereof hereinis meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Unless specified or limitedotherwise, the terms “mounted,” “connected,” “supported,” and “coupled”and variations thereof are used broadly and encompass direct andindirect mountings, connections, supports, and couplings. Further,“connected” and “coupled” are not restricted to physical or mechanicalconnections or couplings.

What is claimed is:
 1. An industrial gas turbine exhaust system,comprising: an inner case; an outer case circumscribing the inner casein spaced relationship relative to a centerline defined by the exhaustsystem; a turbine exhaust path defined between the outer and innercases; and a plurality of struts interposed between the outer and innercases that are tilted at an angle relative to a radius defined by theexhaust system centerline; and a strut collar coupled to an end of atleast one strut and its respective abutting outer or inner case, thecollar outer surface having a constant fillet radius external profile onan acute angle side thereof for smooth exhaust flow transition betweenits respective strut and abutting case surface, the fillet radiusprofile having a range of about 15%-40% of strut maximum thickness. 2.The system of claim 1, the struts having symmetrical airfoil profiles,camber lines of which are aligned parallel with exhaust flow directionin the exhaust path.
 3. The system of claim 2, the airfoil profilehaving a width to chord length ratio of up to approximately 40% and atrailing edge radius between approximately 10%-20% of the strut chordlength.
 4. The system of claim 3, further comprising respective strutcollars coupled to respective ends of each strut and respective abuttingouter or inner case.
 5. The system of claim 1, further comprisingrespective strut collars coupled to respective ends of each strut andrespective abutting outer or inner case.
 6. The system of claim 5, eachstrut collar having generally uniform vertical/radial cross sectionthickness at least on an obtuse angle side of the collar.
 7. The systemof claim 1, further comprising the inner and outer cases adapted forinsertion within a turbine exhaust case (TEC), with the struts orienteddownstream of the TEC.
 8. The system of claim 7, the struts oriented inradially aligned rows in the TEC and downstream the TEC.
 9. The systemof claim 1, each strut collar having a generally uniform vertical/radialcross section thickness at least on an obtuse angle side of the collar.10. An industrial gas turbine apparatus, comprising: a compressorsection; a combustor section; a turbine section including a lastdownstream row of turbine blades that are mounted on a rotating shaft;and an industrial gas turbine exhaust system, having: a turbine exhaustcase (TEC) coupled to a downstream end of the turbine section; an innercase; an outer case circumscribing the inner case in spaced relationshiprelative to a centerline defined by the exhaust system; a turbineexhaust path defined between the outer and inner cases, extendingdownstream of the turbine blades; a plurality of struts interposedbetween the outer and inner cases that are tilted at an angle relativeto a radius defined by the exhaust system centerline; and a strut collarcoupled to an end of at least one strut and its respective abuttingouter or inner case, the collar outer surface having a constant filletradius external profile on an acute angle side thereof for smoothexhaust flow transition between its respective strut and abutting casesurface, the fillet radius profile having a range of about 15%-40% ofstrut maximum thickness.
 11. The apparatus of claim 10, furthercomprising respective strut collars coupled to respective ends of eachstrut and its respective abutting outer or inner case.
 12. The apparatusof claim 10, the plurality of struts axially aligned about the exhaustsystem circumference downstream of the TEC.
 13. The apparatus of claim12, the struts downstream of the TEC having symmetrical airfoilprofiles, camber lines of which are aligned parallel with exhaust flowdirection in the exhaust path.
 14. The apparatus of claim 13, the strutsdownstream of the TEC forming an airfoil profile having a width to chordlength ratio of up to approximately 40% and a trailing edge radiusbetween approximately 10%-20% of the strut chord length.
 15. Theapparatus of claim 10, each strut collar having generally uniformvertical/radial cross section thickness at least on an obtuse angle sideof the collar.
 16. A method for fabricating an industrial gas turbineexhaust system, comprising: simulating an operating gas turbine exhaustflow in a simulated gas turbine exhaust system exhaust path betweeninterior facing surfaces of a simulated turbine exhaust inner case andouter case; providing a plurality of sets of simulated gas turbineexhaust system struts that are tilted at an angle relative to a radiusdefined by the exhaust system centerline and mating strut collars havingdifferent surface profiles, each collar having an outer surface having aconstant fillet radius external profile on an acute angle side thereofand each collar adapted for coupling to an end of its correspondingstrut and a mating inner or outer case interior surface; interposing aplurality of a first set of simulated struts and mating strut collarsbetween the simulated outer and inner cases and monitoring firstsimulated exhaust flow characteristics; interposing a plurality of asecond set of simulated struts and mating strut collars between thesimulated outer and inner cases and monitoring second simulated exhaustflow characteristics; selecting the first or second set of simulatedstruts and mating strut collars for fabrication of a gas turbine exhaustsystem based at least in part on the first and second simulated exhaustflow characteristics; and fabricating a gas turbine exhaust system inconformance with the simulated outer cases and the selected first orsecond set of simulated struts and mating strut collars.
 17. The methodof claim 16, respective struts of the plurality of simulated strut setshaving symmetrical airfoil profiles, camber lines of which are alignedparallel with exhaust flow direction in the exhaust path.
 18. The methodof claim 17, airfoil profile of respective strut of each of theplurality of simulated strut sets having a width to chord length ratiorange of up to approximately 40% and a trailing edge radius betweenapproximately 10%-20% of the strut chord length.
 19. The method of claim18, respective strut collars of the plurality of simulated strut setshaving generally uniform vertical/radial cross section thickness atleast on an obtuse angle side of the collar.
 20. The method of claim 16,respective strut collars of the plurality of simulated strut sets havinggenerally uniform vertical/radial cross section thickness at least on anobtuse angle side of the collar.